Compound injection molded high pressure laminate flooring

ABSTRACT

The invention relates to a method for fabricating a decorative laminate panel, wherein the decorative laminate panel includes a decorative laminate layer and a core. The method is achieved by forming a decorative laminate of a predetermined size, placing the decorative laminate within a die cavity, injection molding the core within the die cavity while the decorative laminate remains within the die cavity to form a decorative laminate panel and releasing the formed decorative laminate panel from the die cavity. The invention further relates to a decorative laminate panel manufactured in accordance with the method defined above and a unitary edge profile member adapted for use in the fabrication of a compound injection molded decorative laminate panel.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The invention relates to a method for the manufacture ofdecorative laminate panels. More particularly, the invention relates toa method for compound injection molding decorative laminate flooringplanks and planks manufactured in accordance with the present method.

[0003] 2. Description of the Prior Art

[0004] Decorative laminate panels, and particularly, decorative laminateflooring planks, are commonly manufactured in a linear manner. That is,the various components move through an extensive processing line wherethe various components are bound, cut, sized, shaped, boxed and shipped.

[0005] The first step in the linear manufacture of decorative laminateflooring is combining the components of the flooring planks.Specifically, the cores, backing layers and decorative panels arecontinuously fed and assembled into large decorative panels requiringsubstantial additional processing before the final product is ready forshipping and use. Once a large decorative panel is completed andinspected, it is conveyed to a processing line where it is machined intoa predetermined number of flooring planks. Finally, the finishedflooring planks are packaged and palletized for shipping.

[0006] It should be understood that the process described herein isdesigned to be continuous. As such, a breakdown occurring at any pointin the line results in the shutdown of the entire processing line untilsuch a time that the problem is corrected. The size of the problem isgenerally irrelevant and the line must be shut down whether a belt ismisaligned or the entire control system goes down.

[0007] The use of line processing further limits productioncapabilities, and necessitates a substantial investment in updating orreplacing equipment segments within a processing line once the capacityof a given equipment segment reaches its production limit. For example,if a packaging segment in a flooring plank processing line is capable ofpackaging 36 boxes of 8 planks per hour, the remainder of the line islimited to this capacity regardless of whether other equipment segmentsare capable of a greater output. The replacement or updating ofequipment segments to raise the overall line output may continue untilsuch a time that the size of the processing line exceeds the allottedspace. The entire processing line must then be moved to a larger spaceor replaced with an entirely new line. Manufacturers, therefore, attemptto maximize the production capabilities of an existing line beforeinvesting substantial sums of money into the creation of a newprocessing line.

[0008] However, increased speed is not always an answer to the need forincreased production. When a processing line is pushed to its limits, itis more likely to break down, resulting in down time. In addition, wherea processing line is operating at maximum capacity, for example, 100flooring planks per minute, errors in processing result in the disposalof all items processed during a given time period. When this occurs,1,500 planks would necessarily be thrown away where planks were beingmanufactured in error for a period of only 15 minutes.

[0009] In accordance with one known production line, the largedecorative panels are formed as approximately 1.22 m×2.44 m sheets. Eachsheet is then cut into a predetermined number of flooring planks. Theedge detail of each plank is then machined and the planks are packagedfor shipping.

[0010] Extensive and expensive cutting tools are used in convertingthese large panels into multiple planks, as well as in machining therequired edge profile into the flooring planks. The extensive use ofcutting tools adds substantial time and expense to the manufacturingprocess. For example, the positioning and wear status of the cuttingtools is continuously monitored to ensure the highest quality in theresulting flooring planks. In addition, the cutting tools are preferablydiamond tipped and maintenance of these diamond tipped cutting toolsadds substantial expense to the manufacturing process.

[0011] In addition to the cost and maintenance problems associated withthe use of conventional cutting tools in the manufacture of flooringplanks, the use of cutting tools limits the possible edge profiles thatmay be formed on the flooring planks. These limitations in turn restrictthe possible designs which might be used to improve the functionality,repairability and installability of flooring planks.

[0012] Current machining techniques used in forming desired edgeprofiles require that substantial portions of the core, decorativelaminate wear surface and backer laminate be machined away. Thisgenerates substantial and undesirable waste.

[0013] As mentioned above, conventional flooring planks are manufacturedwith a decorative laminate wear surface, a backing layer and a corepositioned between the wear surface and the backing layer. The use ofcurrent manufacturing techniques severely limits possible variationswhich might improve the structural characteristics of the flooringplanks.

[0014] For example, the core or substrate materials commonly used inconventional flooring planks are wood-based and, therefore, susceptibleto the effects of moisture. Moisture renders wood-based substrateshighly susceptible to warping, shrinkage, and separation between thedecorative laminate wear surface, backer layer and the core. Sincecurrent flooring plank manufacturing techniques have been developed toprimarily handle wood-based core materials, their adaptation formanufacturing flooring planks utilizing alternate, waterproof, corematerials is thought to be impractical.

[0015] In addition to the water damage to which wood-based flooringplanks are susceptible, the use of wood-based core materialssubstantially extends the time required for producing flooring planks.Before a core material may enter the processing line, the core material,for example, medium density fiberboard, must sit in a controlledenvironment for a period of approximately 24 hours to 72 hours to ensureproper temperature equilibration. Similarly, once the wear surface andbacking layer are bonded to the core, and the flooring plank is formed,the finished flooring plank must further sit and equilibrate for anadditional 24 hours to 72 hours. This final sitting period allows forthe dissipation of stresses from the formed panel.

[0016] The extended sitting periods required in the manufacture ofdecorative laminate flooring planks necessitate that substantial storagespace be provided. The extended sitting periods further leave the corematerials and finished flooring planks susceptible to damage during thetime in which they are required to sit. For example, core sheets areoften permanently bent or warped during storage and must be thrown away.

[0017] Damage to the formed panels and/or planks is also encountered asa result of the many steps involved in the production thereof. As thoseskilled in the art will certainly appreciate, the components of thepanel are moved many times during production of a flooring plank andeach time the panel, or the components thereof, are moved, there is achance that damage will occur.

[0018] The shortcomings of traditional manufacturing processes used inthe production of decorative laminate flooring planks highlight the needfor a new approach in the manufacture of decorative laminate flooringplanks, as well as other decorative laminate products. The presentinvention provides a new and innovative approach to the manufacture ofdecorative laminate flooring planks and other related decorativelaminate products.

SUMMARY OF THE INVENTION

[0019] It is, therefore, an object of the present invention to provide amethod for fabricating a decorative laminate panel, wherein thedecorative laminate panel includes a decorative laminate layer and acore. The method is achieved by forming a decorative laminate of apredetermined size, placing the decorative laminate within a die cavity,injection molding the core within the die cavity while the decorativelaminate remains within the die cavity to form a decorative laminatepanel and releasing the formed decorative laminate panel from the diecavity.

[0020] It is also an object of the present invention to provide adecorative laminate panel manufactured in accordance with the methoddefined above.

[0021] It is further an object of the present invention to provide aunitary edge profile member adapted for use in the fabrication of acompound injection molded decorative laminate panel. The unitary memberdefines an enclosed space and is shaped and dimensioned for receipt ofan injection molded core. The unitary member further includes a radiallyoutwardly facing wall, the outwardly facing wall including a shapedprofile shaped and dimensioned for engagement with the edge profile ofan adjacent decorative laminate panel.

[0022] Other objects and advantages of the present invention will becomeapparent from the following detailed description when viewed inconjunction with the accompanying drawings, which set forth certainembodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023]FIG. 1 is a flow chart of the present method for the compoundinjection molding of decorative laminate planks.

[0024]FIG. 2 is a cross sectional view of an open die receiving a wearsurface and backing layer in accordance with the present invention.

[0025]FIG. 3 is a cross sectional view of a closed die in which corematerial has been injected.

[0026]FIG. 4 is a cross sectional view of an open die releasing a formedflooring plank in accordance with the present invention.

[0027]FIG. 5 is a flow chart of an alternate embodiment of the presentmethod which includes the use of an edge profile member.

[0028]FIG. 6 is a cross sectional view of an open die receiving a wearsurface, backing layer and edge profile member in accordance with themethod disclosed in FIG. 5.

[0029]FIG. 7 is a top view of the lower die member shown in FIG. 6 withthe edge profile member therein.

[0030]FIG. 8 is a cross sectional view of a closed die in which corematerial has been injected in accordance with the method disclosed withreference to FIG. 5.

[0031]FIG. 9 is cross sectional view of an open die releasing a formedflooring plank in accordance with the method disclosed in FIG. 5.

[0032]FIG. 10 is a cross sectional view of an open die receiving a wearsurface, backing layer and edge profile members in accordance with analternate method.

[0033]FIG. 11 is a top view of the lower die member shown in FIG. 10with the edge profile member thereon.

[0034]FIG. 12 is cross sectional view of an open die releasing a formedflooring plank in accordance with the embodiment described withreference to FIG. 10.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] The detailed embodiments of the present invention are disclosedherein. It should be understood, however, that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, the details disclosed herein are not to be interpretedas limited, but merely as the basis for the claims and as a basis forteaching one skilled in the art how to make and/or use the invention.

[0036] With reference to FIG. 1, a flow chart of a preferred method inaccordance with the present invention is disclosed. The method generallyrelates to the manufacture of decorative laminate panels, andparticularly, the manufacture of decorative laminate flooring planks.The present method provides for the compound injection molding ofdecorative laminate flooring planks in a piecewise manner. Thiseliminates the problems associated with conventional line techniquesemployed in the prior art and discussed above in the “Background of theInvention”.

[0037] The term “flooring planks” is used throughout the body of thepresent specification in describing decorative laminate flooring panels,and should not be interpreted as limiting the scope of the invention toflooring panels of any specific shape. In fact, the present inventionopens the possibility for the manufacture of flooring plank shapespreviously considered cost prohibitive.

[0038] As outlined in FIG. 1 and as shown in FIGS. 2, 3 and 4, adecorative laminate wear surface 12 is first produced and cut intoappropriate sizes for use in conjunction with the compound injectionmold die 17 employed in accordance with the present process. Cutting isachieved using conventional sizing techniques adapted to cut laminatesheets to desired sizes and shapes. Such cutting techniques are wellknown to those skilled in the art.

[0039] In accordance with a preferred embodiment of the presentinvention, the decorative laminate wear surface 12 is generally cut ineither 39.4 cm by 39.4 cm squares or 118.1 cm by 19.7 cm rectangles, asthese are commonly used shapes in the fabrication and installation ofdecorative laminate flooring. As will be better appreciated based uponthe foregoing disclosure, the cut sheets of decorative laminate are cutslightly larger than specified above (for example, about 0.381 mm to0.762 mm) to allow for final processing including the removal ofoverhang portions from the decorative laminate wear surface 12 for finalsizing and squaring of the plank.

[0040] Similarly, the backing layer 14 is also produced and cut intoappropriate sizes for use in conjunction with the compound injectionmold die 17. As with the decorative laminate wear surface 12, cutting isachieved using conventional laminate sizing techniques which may bereadily adapted to cut laminate sheets to desired sizes and shapes. Thebacking layer 14 is cut to a shape substantially matching, but slightlysmaller than, that of the decorative laminate wear surface 12. However,the backing layer 14 is hidden from the end user's view and it is notcritical that the appearance of the backing layer 14 be maintained atthe same high standards as those applied to the decorative laminate wearsurface 12.

[0041] While preferred shapes and dimensions are disclosed above, thedecorative laminate wear surface 12 and backing layer 14 may be cut intoa variety of shapes without departing from the spirit of the presentinvention. In fact, the present invention allows for the production of awide variety of shaped panels (for example, octagons, triangles, etc.).

[0042] In addition, it is contemplated that various cutting techniquesknown to those skilled in the art may be employed in accordance with thepresent invention. In fact, the cutting of the decorative laminate wearsurfaces 12 and backing layers 14 need not take place immediately beforethe injection molding steps. The decorative laminate wear surfaces 12and backing layers 14 may be cut to size and stored under appropriateconditions for later use.

[0043] However, it is contemplated that the cutting step and theinjection molding step will take place as part of a continuous processwith the laminate wear surfaces 12 and backing layers 14 being cut justprior to the preconditioning and formation of the complete laminateflooring planks 20. Such a continuous system is believed to be more costeffective since the necessity for storing precut laminate sheets wouldadd additional expense to the process.

[0044] Once formed, the cut decorative laminate wear surfaces 12 andbacking layers 14 are preconditioned and conveyed to a die cavity 16(see FIG. 2). The step of preconditioning allows the cut decorativelaminate wear surfaces 12 and backing layers 14 to be physicallyprepared in order to optimize the bond created between the core 18, thecut decorative laminate wear surface 12 and the backing layer 14.

[0045] Briefly, and as will be discussed below in greater detail, whenthe cut decorative laminate wear surface 12 and backing layer 14 areplaced within the die cavity 16, the die 17 is closed and core materialis injected within the die cavity 16 to create a panel core 18 (see FIG.3). The core material is chosen to ensure the formation of a secure bondbetween the formed core 18, the decorative laminate wear surface 12 andbacking layer 14 as the molten core material is shot within the diecavity 16.

[0046] In accordance with a preferred embodiment of the presentinvention and considering the versatility provided by compound moldingtechniques, it is contemplated that the core may be formed from a widevariety of materials. For example, the core may be formed from filledplastics, unfilled plastics, ceramics, fibers, polymeric foams, andcombinations thereof. In practice, it is contemplated that the corematerials will be chosen to suit specific requirements associated withthe intended use of the flooring planks. For example, it is contemplatedthat virgin water repellant materials will be used where the planks arelikely to be exposed to moisture on a regular basis. However, recycledplastics and plastics including various wood-based products may be usedin situations where it is unlikely that the flooring planks will beexposed to moisture.

[0047] While contemplated materials are listed above as being exemplaryof those materials which may be used in accordance with the presentinvention, it should be understood that a wide variety of materials maybe used without departing from the spirit of the present invention.

[0048] After the injection of the core material, the cavity 16 remainsclosed for a period of time sufficient to allow the flooring plank 20 toset. Finally, the die 17 is opened, the resulting molded flooring plank20 is released from the die cavity 16, and the flooring plank 20 ismoved to a fixture where the flooring plank 20 is precision machined,for example, CNC machined. The finished plank 20 is then conveyed forpackaging and transport.

[0049] Specifically, the flooring plank 20 is machined to remove edgesof the decorative laminate wear surface 12 to ensure that hightolerances are maintained. By machining the edges of the decorativelaminate wear surface 12 after the injection molding step, one is ableto remove irregularities in the edges of the wear surface 12 which mayhave occurred prior to molding and square the plank 20 to a highertolerance than previously possible during the initial cutting steps.

[0050] While the flooring planks described above are manufactured with abacking layer, it is contemplated that various core materials may permitthe manufacture of flooring planks without the need for the inclusion ofa backing layer. Where such panels are formed in accordance with thepresent invention, the substrate thereof may be formed with structuralribbing designed to add structural stability to the final panel.Structural ribbing may also be included in panels having a backinglayer, although it is believed the inclusion of structural ribbing wouldfind more wide spread applications in instances where the backing layeris not formed with the decorative laminate panel.

[0051] By compound injection molding the decorative flooring planks inaccordance with the present invention, many shortcomings of prior artline processing techniques are overcome. For example, limited tooling isrequired for injection molding the decorative laminate flooring planks.In addition, virtually the entire line now used to manufacturedecorative laminate flooring planks could be replaced by a cuttingassembly for the decorative laminate wear surface, a cutting assemblyfor the backing layer, a preliminary conditioning station for the wearsurface and backing layer, a plurality of injection molding dies andfinal processing machinery; providing a substantial savings in bothspace and tooling.

[0052] The result of such a process is a reduction in the toolingrequired for the processing of decorative laminate flooring planks and alimited number of stations which might break down. In fact, if thedecorative laminate wear surface and the backing layer are cut apartfrom the injection molding step, only the preconditioning step precedesthe injection molding of the decorative laminate flooring planks. Inaddition, by using multiple injection molding cavities, a shutdown of asingle cavity slows down the fabrication process by one machine and doesnot shut down an entire line as would occur where a machine breaks downin the prior art line processing techniques.

[0053] The present compound injection molding process also permits thecreation of unique edge profiles, which would be cost prohibitive, oreven impossible, using conventional cutting techniques employed in thelinear processing of decorative laminate flooring planks. When compoundinjection molding techniques are employed, the edge profiles which maybe created are only limited by the creativity of those designing theflooring planks. For example, interlocking planks such as thosedisclosed in U.S. Pat. No. 5,618,602, entitled “Articles with Tongue andGroove Joint and Method of Making Such a Joint”, would be easilymanufactured in accordance with the present invention.

[0054] Similarly, where prior flooring planks commonly include a flatbacking surface, the use of compound injection molding in themanufacture of decorative laminate flooring planks would readily permitthe manufacture of flooring planks exhibiting a variety of shapes andtextures enhancing the functionality of the decorative laminate flooringplanks.

[0055] An alternate embodiment of the present invention is disclosed inFIGS. 5 to 9. This embodiment takes advantage of a separate edge profilemember 115 to enhance the water repellence of the flooring planks 120and expand upon the possible edge profiles which may be employed inaccordance with the present invention. The edge profile member 115defines a “window frame” positioned between the decorative laminate wearsurface 112 and the backing layer 114. The edge profile member 115further provides an outer edge on the final decorative laminate flooringplank 120 shaped and dimensioned for permitting ready attachment toadjacent flooring planks 120.

[0056] Specifically, and as with the embodiment disclosed in FIGS. 1 to4, the decorative laminate wear surface 112 is first produced and thencut into appropriate sizes for use in conjunction with the compoundinjection mold dies 117 employed in accordance with the present process.The decorative laminate wear surface 112 is generally cut in either 39.4cm by 39.4 cm squares or 118.1 cm by 19.7 cm rectangles. As will bebetter appreciated based upon the foregoing disclosure, the cut sheetsof decorative laminate are slightly larger (for example, about 0.381 mmto 0.762 mm) to allow for final processing which may remove edgeportions of the decorative laminate wear surface 112.

[0057] Similarly, the backing layer 114 is also produced and cut intoappropriate sizes for use in conjunction with the compound injectionmold dies 117 employed in accordance with the present process. As withthe decorative laminate wear surface 112, cutting is achieved usingconventional laminate sizing techniques which may be readily adapted tocut laminate sheets to desired sizes and shapes. The backing layer 114is cut to a shape substantially matching, but slightly smaller than,that of the decorative laminate wear surface 112.

[0058] While the backing layer 114 and decorative laminate wear surface112 are being produced and cut into appropriate sizes, the edge profilemember 115 is also produced. The edge profile member 115 is preferablyinjection molded with a desired edge profile and inner surface. The edgeprofile member may then be machined to remove any undesired markingsremaining after the injection molding thereof.

[0059] The edge profile member 115 is preferably injection molded fromwater repellant thermoplastic materials, including, but not limited to,vinyls, polyolefins, styrenics, polyamides, polyimides, polyethers,polyesters, acrylics, acetals, thermoplastic olefins, thermoplasticurethanes and thermoplastic elastomers. In addition, it is alsoenvisioned that the edge member may be formed from thermoset materials,such as, epoxies, polyurethanes, phenolics, melamines, etc. It isfurther contemplated that the edge member may be a foamed thermoplastic.More specifically, the edge profile member 115 is preferably formed fromacrylic-butadiene-styrene (ABS), although other materials may be usedwithout departing from the spirit of the present invention. As thoseskilled in the art of injection molding will understand, the edgeprofile member should be formed from a material having a higher meltingtemperature than that of the core material. This allows for injectionmolding of the core without adversely affecting the previously formededge profile member 115.

[0060] As those skilled in the art will certainly appreciate, an almostinfinite variety of edge profiles may be applied to the edge profilemember 115 through the use of injection molding. In addition, injectionmolding of the edge profile member 115 provides highly reproducibleresults ensuring consistent fitting of flooring planks 120 manufacturedin accordance with the present invention.

[0061] While the edge profile member is injection molded in accordancewith a preferred embodiment of the present invention, it is contemplatedthat the edge profile member may be extruded as multiple pieces (seedisclosure below), or otherwise produced, without departing from thespirit of the present invention.

[0062] Referring to FIGS. 6, 7, 8 and 9, once formed the cut decorativelaminate wear surfaces 112, backing layers 114 and edge profile members115 are preconditioned and conveyed to a die cavity 116. The step ofpreconditioning allows the cut decorative laminate wear surfaces 112,backing layers 114 and edge profile members 115 to be physicallyprepared in order to optimize the bond created between the core 118, thecut decorative laminate wear surface 112, the backing layer 114 and edgeprofile member 115.

[0063] The cut decorative laminate wear surfaces 112, backing layers 114and edge profile members 115 are then positioned one at a time forprocessing within the die cavity 116 of the die 117. Briefly, and aswill be discussed below in greater detail, when the cut decorativelaminate wear surface 112, backing layer 114 and edge profile member 115are placed within the die cavity 116, the die 1 17 is closed and corematerial is injected within the die cavity 116 to create a panel core118. The core material is chosen to ensure the formation of a securebond between the formed core 118 and the decorative laminate wearsurface 112, the backing layer 114 and the edge profile member 11 5 asthe molten core material is shot within the die cavity 116.

[0064] As discussed above, it is contemplated that the core 118 may beformed from a wide variety of materials. For example, the core may beformed from filled plastics, unfilled plastics, ceramics, fibers,polymeric foams, and combinations thereof. In practice, it iscontemplated that the core materials will be chosen to suit specificrequirements associated with the intended use of the flooring planks.However, and in contrast to the embodiment discussed above withreference to FIGS. 1 to 4, the core material need not be waterproof asthe edge profile member 115 will substantially protect the core 118 fromwater penetration entering from the sides of the formed flooring planks120. This permits the use of recycled materials which provide desiredstructural rigidity but which do not offer desired compositionalcharacteristics (or for which the compositional characteristics have notbeen determined).

[0065] While contemplated materials are listed above as being exemplaryof those materials which may be used in accordance with the presentinvention, it should be understood that a wide variety of materials maybe used without departing from the spirit of the present invention.

[0066] As mentioned above, the edge profile member 115 is positionedwithin the die cavity 116 to define the edges of the resulting flooringplank 120 and to seal the edges of the injected core 118. The edgeprofile member 115 is, therefore, considered to form a “picture frame”about the edge of the resulting flooring plank 120.

[0067] After the injection of the core material, the die 117 remainsclosed for a period of time sufficient to allow the flooring panel 120to set. Finally, the die 117 is opened, the resulting molded flooringplank 120 is released from the die cavity 116, and the flooring plank120 is moved to a fixture where the flooring plank is precisionmachined, for example, CNC machined. The finished plank 120 is thenconveyed for packaging and transport. Specifically, the flooring plank120 is primarily machined to remove overhang of the decorative laminatewear surface 112 so as to ensure high tolerances are maintained.

[0068] As with the embodiment discussed above with regard to FIGS. 1 to4, the flooring planks 120 described in accordance with the disclosedembodiment are manufactured with a backing layer. However, it iscontemplated that various core materials may permit the manufacture offlooring planks without the need for the inclusion of a backing layer.

[0069] As mentioned above with regard to the embodiment disclosed inFIGS. 5 to 9, and with reference to FIGS. 10 to 12, the frame definingthe edge of the flooring plank may be composed of multiple edge profilemembers assembled to form a frame. Specifically, these edge profilemembers 215 are produced while the backing layer 214 and decorativelaminate wear surface 212 are being produced and cut into appropriatesizes.

[0070] The edge profile members 215 are preferably injection molded witha desired edge profile and subsequently cut (if necessary) to length foruse in the molding step. The edge profile members 215 are preferablyinjection molded from water repellant plastics as listed above. Whilethe edge profile members are injection molded in accordance with apreferred embodiment of the present invention, it is contemplated thatthe edge profile members may be extruded, or otherwise produced, withoutdeparting from the spirit of the present invention.

[0071] The cut decorative laminate wear surfaces 212, backing layers 214and edge profile members 215 are then assembled and molded in the mannerdiscussed above with reference to FIGS. 6, 7, 8 and 9. The onlydifference being that the edge profile members 215 must be individuallypositioned about the circumference of the cavity 216, as opposed to thesingle piece edge profile member 115 employed in accordance with theembodiment previously discussed.

[0072] While the preferred embodiments have been shown and described, itwill be understood that there is no intent to limit the invention bysuch disclosure, but rather, is intended to cover all modifications andalternate constructions falling within the spirit and scope of theinvention as defined in the appended claims.

1. A method for fabricating a decorative laminate panel, wherein thedecorative laminate panel includes a decorative laminate layer and acore, the method comprising the following steps: forming a decorativelaminate of a predetermined size; placing the decorative laminate withina die cavity; injection molding the core within the die cavity while thedecorative laminate remains within the die cavity to form a decorativelaminate panel; and releasing the formed decorative laminate panel fromthe die cavity.
 2. The method according to claim 1, wherein thedecorative laminate panel is a flooring plank.
 3. The method accordingto claim 1, wherein the core is composed of a material chosen from thegroup consisting of filled plastics, unfilled plastics, ceramics,fibers, polymeric foams, and combinations thereof.
 4. The methodaccording to claim 1, wherein the step of forming includes cutting adecorative laminate sheet to a predetermined size to form a cutdecorative laminate.
 5. The method according to claim 1, wherein thedecorative laminate panel includes a backing layer, and the methodincludes the further step of placing the backing layer within the diecavity.
 6. The method according to claim 5, including the step offorming at least one edge profile member and placing the at least oneedge profile member between the decorative laminate and the backinglayer within the die cavity for use in the formation of the decorativelaminate panel.
 7. The method according to claim 6, wherein thedecorative laminate panel is a flooring panel.
 8. The method accordingto claim 6, wherein the edge profile member is formed from a materialchosen from the group consisting of vinyls, polyolefins, styrenics,polyamides, polyimides, polyethers, polyesters, acrylics, acetals,thermoplastic olefins, thermoplastic urethanes, thermoplasticelastomers, epoxies, polyurethanes, phenolics and melamines.
 9. Themethod according to claim 8, wherein the edge profile member is formedfrom acrylic-butadiene-styrene.
 10. The method according to claim 6,wherein the step of forming the edge profile member includes injectionmolding the edge profile member.
 11. The method according to claim 5,wherein the decorative laminate panel is a flooring plank.
 12. Themethod according to claim 5, wherein the backing layer is formed by theadditional step of cutting a decorative backing layer to a predeterminedsize to form a cut backing layer.
 13. The method according to claim 1,including the step of forming at least one edge profile member andplacing the at least one edge profile member within the die cavity foruse in the formation of the decorative laminate panel.
 14. The methodaccording to claim 13, wherein the decorative laminate panel is aflooring panel.
 15. The method according to claim 13, wherein the edgeprofile member is formed from a material chosen from the groupconsisting of vinyls, polyolefins, styrenics, polyamides, polyimides,polyethers, polyesters, acrylics, acetals, thermoplastic olefins,thermoplastic urethanes, thermoplastic elastomers, epoxies, polyethanes,phenolics and melamines.
 16. The method according to claim 15, whereinthe edge profile member is formed from acrylic-butadien e-styrene. 17.The method according to claim 13, wherein the step of forming the edgeprofile member includes injection molding the edge profile member. 18.The method according to claim 13, wherein the step of placing includespositioning the edge profile member beneath the decorative laminate suchthat it defines an outer edge of the formed decorative laminate panel.19. A decorative laminate panel, comprising: a decorative laminate; aunitary edge profile member defining the circumference of the resultinglaminate panel; and an injection molded core beneath the decorativelaminate and within a space defined by an interior wall of the edgeprofile member.
 20. The decorative laminate panel according to claim 19,wherein the edge profile member includes an outer wall defining an edgeprofile facilitating interlocking engagement with adjacent similarpanels.
 21. The decorative laminate panel according to claim 19, whereinthe edge profile member is formed from a material chosen from the groupconsisting of vinyls, polyolefins, styrenics, polyamides, polyimides,polyethers, polyesters, acrylics, acetals, thermoplastic olefins,thermoplastic urethanes, thermoplastic elastomers, epoxies,polyurethanes, phenolics and melamines.
 22. The decorative laminatepanel according to claim 21, wherein the edge profile member is formedfrom acrylic-butadiene-styrene.
 23. The decorative laminate panelaccording to claim 22, further including a backing layer.
 24. Thedecorative laminate panel according to claim 19, wherein the panel is aflooring plank.
 25. A unitary edge profile member adapted for use in thefabrication of a compound injection molded decorative laminate panel,comprising: a unitary member defining an enclosed space, the unitarymember being shaped and dimensioned for receipt of an injection moldedcore; and the unitary member further including a radially outwardlyfacing wall, the outwardly facing wall including a shaped profile, theshaped profile being shaped and dimensioned for engagement with the edgeprofile of an adjacent decorative laminate panel.
 26. The edge profilemember according to claim 25, wherein the unitary member is formed froma material chosen from the group consisting of vinyls, polyolefins,styrenics, polyamides, polyimides, polyethers, polyesters, acrylics,acetals, thermoplastic olefins, thermoplastic urethanes, thermoplasticelastomers, epoxies, polyurethanes, phenolics and melamines.
 27. Theedge profile member according to claim 26, wherein the unitary member isformed from acrylic-butadiene-styrene.